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Piping and Pumping
Piping and Pumping
Syracuse University
Process Design
CEN 574
Spring 2004
Outline
• Pipe routing
• Optimum pipe diameter
• Pressure drop through piping
• Piping costs
• Pump types and characteristics
• Pump curves
• NPSH and cavitation
• Regulation of flow
• Pump installation design
Piping and Pumping
Learning Objectives
At the end of this section, you should be able to…
• Draw a three dimensional pipe routing with
layout and plan views.
• Calculate the optimum pipe diameter for an
application.
• Calculate the pressure drop through a length of
pipe with associated valves.
• Estimate the cost of a piping run including
installation, insulation, and hangars.
• List the types of pumps, their characteristics, and
select an appropriate type for a specified application.
• Draw the typical flow control loop for a centrifugal
pump on a P&ID.
• Describe the features of a pump curve.
• Use a pump curve to select an appropriate pump and
impellor size for an application.
• Predict the outcome from a pump impellor change.
• Define cavitation and the pressure profile within a
centrifugal pump.
• Calculate the required NPSH for a given pump
installation.
• Identify the appropriate steps to design a pump
installation.
References
• Appendix III.3 (pg 642-46) in Seider et al.,
Process Design Principals (our text for this
class).
• Chapter 12 in Turton et al., Analysis, Synthesis,
and Design of Chemical Processes.
• Chapter 13 in Peters and Timmerhaus, Plant
Design and Economics for Chemical Engineers.
• Chapter 8 in McCabe, Smith and Harriott, Unit
Operations of Chemical Engineering.
Pipe Routing
• The following figures show a layout
(looking from the top) and plan
(looking from the side) view of
vessels.
• We want to rout pipe from
the feed tank to the reactor.
reactor piping
Plan View chase
steam
header 40 ft
feed 60 ft
tank
50 ft 35 ft
Layout View: Looking Down
steam
40 ft
header
feed 45 ft piping
tank chase
30 ft reactor 10 ft
reactor
50 ft 35 ft
Plan View reactor piping
= out chase
= in
steam
header 40 ft
feed
60 ft
tank
50 ft 35 ft
Layout View
steam
header
85 ft
30 ft
feed 20 ft
tank
35 ft 60 ft
10 ft
10 ft
reactor
Pipe Routing Exercise
• Form groups of two.
• Draw a three dimensional routing
for pipe from the steam header to
the feed tank on both the plan view
and the layout view.
Size the Pump
1. Determine optimum pipe size.
2. Determine pressure drop through pipe
run.
200 ft
globe
valve
check valve 150 ft
100 gpm
Optimum Pipe Diameter
The optimum pipe diameter gives
the least total cost for annual
pumping power and fixed costs. As
D , fixed costs , but pumping
power costs .
Optimum Pipe Diameter
Total Cost
Cost/(year ft)
Annualized Pumping
Capital Cost Power Cost
Optimum
Pipe Diameter
Example
• Two methods to determine the
optimum diameter:
Velocity guidelines and Nomograph.
Sum K = 19.5
• hL due to fittings = c3Ksumq2/d4 = 5.7 ft
of liquid head loss due to fittings.
• hLsum=7.2 + 5.7 ft of liquid head loss
• Using Bernoulli Equation
P = (/144)(Z+[v22-v12]/2g+hLsum)
50 ft
check valve
Note:
not
2003 $
Pumps – Moving Liquids
• Centrifugal
• Positive displacement
– Reciprocating: fluid chamber
stationary, check valves
– Rotary: fluid chamber moves
Centrifugal Pumps
Centrifugal Pump Impeller
Positive Displacement:
Reciprocating
• Piston: up to 50 atm
• Plunger: up to 1,500 atm
• Diaphragm: up to 100 atm, ideal for
corrosive fluids
• Efficiency 40-50% for small pumps,
70-90% for large pumps
Positive Displacement:
Reciprocating (plunger)
Positive Displacement:
Rotary
- used to determine
which pump to
purchase.
- provided by the
manufacturer.
Pump Curve
Low flow at
high head
Pressure
increases
with diameter
Head
sensitive
to flow
at high
flow
rates
NPSH and Cavitation
• NPSH = Net Positive Suction Head
• Frictional losses at the entrance to the
pump cause the liquid pressure to drop
upon entering the pump.
• If the the feed is saturated, a reduction in
pressure will result in vaporization of the
liquid.
• Vaporization = bubbles, large volume
changes, damage to the pump (noise and
corrosion).
Pressure
Profile
in the
Pump
NPSH
• To install a pump, the actual NPSH must be equal
to or greater than the required NPSH, which is
supplied by the manufacturer.
• Typically, NPSH required for small pumps is 2-4
psi, and for large pumps is 22 psi.
• To calculate actual NPSH…
NPSHactual= Pinlet-P* (vapor pressure)
FV
FT
Designing Pump Installations
• use existing pump vendor, note spare
parts the plant already stocks.
• select desired operating flow rate,
maximum flow rate.
• calculate pressure drop through discharge
piping, fittings, instrumentation (note if
flow control is desired need to use
pressure drop with control valve 50%
open).
• add safety factor to calculated head – 10
psig spec pump for 20 psig, 150 psig
spec pump for 200 psig.
• using head and flow rate, select impeller
that gives efficient operation in region of
operating flow rate.
• vertical location of pump compared to
level of influent tank (NPSH).
• if want to control flow rate – spec and
order flow meter and flow control valve
also.